Apparatus for forming plates of irregular shape in cross-section

ABSTRACT

A plate-form die is used in combination with a reciprocating roller, a strip of plate material being passed incrementally between the roller and die. The die includes a wedge shaped leading end portion to form a groove in the plate material.

United States Patent Fnkuda Feb. 19, 1974 APPARATUS FOR FORMING PLATES OF IRREGULAR SHAPE IN CROSS-SECTION [56] References Cited [75] Inventor: Hiroshi Fukuda, Iwata, Japan UNITED STATES PATENTS Assignee: Kabushiki Kaisha Kawai et a1. Seisakusho, Hamamatswshi 1,725,594 8/1929 Montgomery 72/220 Shlzuokwken Japan Primary ExaminerMilton S. Melnr Filed: g- 30, 1972 Attorney, Agent, or Firm-Eric H. Waters [21] Appl. No.: 284,869

[57] ABSTRACT [30] Foreign Application Priority Data A plate-form die is nsed in combinatipn with a reciprocatmg roller, a strip of plate material being passed Aug. 19, Japan nc e y between the roller a The cludes a wedge shaped leading end portion to form a [52] US. Cl. 72/220 51 Int. Cl B2ld 7/02 the plate matena" [58] Field of Search 72/220; 425/374 11 Claims, 14 Drawing Figures PATENTED FEB] 9 I974 SHEEI l M Q PATENTEI] FEB I 9 I974 SHEET 3 OF 4 PATENTED FEB] 91974 SHEH lb 0? 4 APPARATUS FOR FORMING PLATES OF IRREGULAR SHAPE IN CROSS-SECTION FIELD OF INVENTION The invention relates to methods and apparatus for forming plates of irregular shape in section and which have a small-thickness portion and a large-thickness portion, the plates being formed out of a comparatively thick plate material. The invention relates more particularly to methods and apparatus for forming parts such as contact members for connectors, contact members for relays, terminal members for wrapping connections, reeds for musical instruments and the like.

BACKGROUND The material to be used for making the above types of products must be a material having a comparatively high elasticity such as copper alloys including, for example, phosphor bronze, brass or copper nickel alloy, nickel silver, stainless steel or the like.

For forming plates of irregular sectional shape of this kind of material, there have been hitherto practiced a rolling process, a cutting process and a rolling and cutting combination process.

The rolling process is a process in which a plate material is passed between rolls for being extended in the longitudinal direction thereof. This process is defective in that the extension of the plate material in its width direction is very small. Accordingly, when the center portion thereof is intended to be made thin, there is a limit to the thinning of that portion and there is brought about a waving phenomenon if a certain limit is exceeded. Further, the material can be broken if it is thinned out.

In the cutting process, the material is fed to a rotating or stationary cutter to be cut thereby. This process is defective in that there is brought about a waste of material by the cutting. Further, continuous cutting for materials of great length cannot be achieved.

In the case of the combination process, the respective defects of the above two processes are somewhat avoided and the material can be made somewhat thinner, compared with the respective foregoing processes. However, it is still difficult to continuously form a material of great length.

SUMMARY OF THE INVENTION This invention has for an object the provision of an apparatus free from the foregoing defects.

The invention is characterized in that, opposite to a plate surface of a plate-form die which issharpened at its front end portion, there is provided a pressure roller which rolls within a range corresponding to the plate surface of the die for pressing a plate material placed on the plate surface. At the completion of each pressing action of the pressure roller, the plate material is moved by a predetermined length rearwards from the front end portion of the plate-form die.

BRIEF DESCRIPTION OF THE DRAWING Embodiments of this invention will next be explained with reference to the accompanying drawings in which:

FIG. 1 is a generalized top plan view of one embodiment of this invention;

FIG. 2 is a side elevational view of the same;

FIG. 3 is a sectional view taken along line III III in FIG. 1;

FIG. 4 is a sectional view taken along line IV IV in FIG. 1;

FIG. 5 is a side view of a more specific embodiment of this invention;

FIG. 6 is a top plan view as seen from Y in FIG. 5;

FIG. 7 is a top plan view as seen from Z in FIG. 5;

FIG. 8 is a sectional view taken along line VIII VIII in FIG. 6;

FIG. 9 is a top plan view of a flat plate-form of die of a different type;

FIG. 10 is a sectional view taken along line X X in FIG. 9;

FIG. 11 is a perspective view of a product obtained by a die of this type;

FIG. 12 is a top plan view of a flat plate-form die of another different type;

FIG. 13 is a sectional view taken along line XIII XIII in FIG. 12; and

FIG. 14 is a perspective view of a product obtained by the die of this type.

DETAILED DESCRIPTION In FIGS. I to 3, component I is a flat plate-form die which is sharpened at its front end] portion 1a to have an acute angle. A plate material a is put at its one end portion on the upper surface of the plate-form die 1.

A pressure roller 2 which rolls within the range extending from the front end of the flat die 1 to the rear end thereof is provided opposite the die I. It is arranged that the plate material a is repeatedly moved by a predetermined length S rearwards from the wedgeshaped front or leading end portion 1a of the die 1 after each completion of a reciprocating movement of the roller, for example, from a position A to a position B and back to the position A while pushing the plate material a against the flat plate-form die I.

Thus, the plate material a is gradually squeezed by the die 1 from its sharpened front end portion la to the maximum width of the rear end lb thereof, so that the center portion of the material a can be formed with a portion of small thickness, that is, a thinner portion, and thereby a long piece of irregular sectional shape as shown in FIG. 4 can be obtained.

The plate of irregular shape in section b thus obtained is further applied to a rolling machine (not shown) for being formed into a desired txickness. The resultant piece is then properly cut to length to obtain products such as contact members or terminal members or the like each having a portion of small thickness and a portion of large thickness.

In the above explanation, the plate-form die 1 is only sharpened at its leading or front end portion. In this case, however, the small thickness portion of the material a can be damaged or broken by the influence of the opposite side edges of the sharpened portion 1a. Therefore these edges must be formed into slanted surfaces lc (slanted at an angle hereinafter called the angle of reliefB) as illustrated in FIG. 3. The tip of the sharpened portion In is thus naturally formed into a knife edge by this angle of relief B. However, the small thickness portion of the material a can also be damaged by a corner resulting between the inclination of the tip end and the plate surface of the die 1. Therefore, the same portion must be chamfered as at 111. This chamfered portion 1d may be either a plane surface or a curved surface.

The plate-form die 1 is provided with a broad width portion 1e extending rearwardly from the rear end lb of the sharpened portion la and having the same width as the maximum width thereof. The portion 1e should extend over a length corresponding to the length of travel of the material a for each step thereof. Thus, a plate of irregular sectional shape b can be moved in a straight line by being guided by this broad width portion 1e.

In one example, wherein a plate material a of brass (copper 70% zinc 30%) of 2.0 mms. in thickness and 50 mms. in width is formed at its center portion with a small thickness portion of 30 mms. in width, the minimum thickness obtainable with different angles of relief [3 is 0.42 mm. at 15, 0.59 mm. at 30 and 0.79 mm. at 45. A plate of irregular sectional shape can thus be easily rolled by a rolling machine, whereby the small thickness portion thereof is made to be 0.1 0.15 mm. and the large thickness portion thereof is made to be about 0.45 mm. By cutting the same, contact members for a relay, for example, can be obtained therefrom.

The pressure roller 2 is not limited to a reciprocating movement from the postion A but can have a reciprocating movement from the position B. It is preferable that, at the time of movement of the plate form material a, the pressing action by the pressure roll 2 be released, however the material a can also be moved without being released.

FIG. shows a specified embodiment whereby a plate of irregular sectional shape and of great length can be continuously formed. In this embodiment, the pressure roller 2 is rotatably supported on a machine frame 5 provided reciprocably on a machine base 3 by rollers 4. The machine frame 5 is connected through a crank 6 to a rotary disk 8 rotated by a prime mover 7.

The plate-form die 1 has a pressing apparatus 9 thereon provided just above the pressure roller 2 so as to face the same. The plate material a which is of long size is pulled out from a winding frame 10 and is passed between the pressure roller 2 and the plate form of die 1.The plate material is connected at its front portion to a winding frame 11.

Component 12 is a clamp-type travelling apparatus for intermittently moving the plate material a by a predetermined length S. It comprises as shown in FIGS. 5 and 6, a slidable frame 13, a L-shaped swingable arm 16 which is in contact at it's one end with the periphery of a cam plate 14 that is arranged to rotate with the reciprocating movement of the machine frame 5 carrying the pressure roller 2. It is provided at its other end with a pressure plate 15 and a receiving plate 17 formed integrally with the slidable frame 13 on the upper surface of the material a so as to be aligned with the pressure plate 15. Component 18 is a spring which pulls the slidable frame 13 toward the retreating side and component 16' is a roller provided on one end portion of the L-shaped swingable arm 16.

When the rotation of the rotary disk 8 causes the cam plate 14 to push the roller 16, the swingable arm 16 is inclined and accordingly the pressure plate 15 on the other end thereof is elevated, whereby the plate material a is clamped between the pressure plate 15 and the receiving plate 17. Even though the rotary disk 8 is further rotated, owing to the fact that the swingable arm 16 cannot be inclined any more, the slidable frame 13 is moved to the right, that is, it retreats against the action of the spring 18, whereby the plate material a is moved to the right.

The pressing apparatus 9 comprises, as shown clearly in FIGS. 5 and 7, a pair ofwedge members 19 provided on the rear surface, that is, the upper surface of the plate-form die 1. These wedge members 19 are each in threaded engagement at the corresponding base end portion with a threaded rod 20. A gear 21 mounted on the base portion of each rod 20 is in mesh with a gear 23 which is rotated by a handle 22 so that, by rotating the handle 22, the rods 20 are rotated and the wedge members 19 are advanced or pulled back whereby the pushing force exerted on the plate-form die 1 can be adjusted.

Component 24 is a holding rod for the die 1. it comprises a threaded portion 24a on the tip end thereof which is screwed into a base plate 26 which is integral with the plate-form die 1.

Component 27 are fixing devices for the plate material a provided on the front and rear sides of the location of the die 1 and the pressure roller 2. These devices each comprise a receiving plate 28 provided on the lower surface of the flat plate material a and a pres sure plate 31 provided on the tip end of a piston rod 30 of a fluid pressure cylinder 29. On rolling of the pressure roller 2, the piston rod 30 is lowered to the pressure plate 31 to fix the plate material a but, on advancing of the material a, the pressing action of the piston rod 30 thereon is released.

component 32 is a prime mover for driving the wind ing frame 11. It is so arranged as to drive on movement of the clamp-type travelling apparatus 12 so that the length of the material a travelled by the apparatus 12 can be taken up on the winding frame 11. Component 33 is a pulley provided ona driving shaft 34 for the rotary disk 8. The pulley is connected to the prime mover 7 through a belt 35.

Part 1f denotes a concavity made in the rear surface of the broad width portion 12 located just above the rear end portion of the die 1. It is so arranged that the pressure roller 2 is located thereon when it completes its reciprocating movement, whereby the pushing action of the roller 2 on the material a may be released. As a result, the movement of the plate material a is facilitated.

Next, the operation of this apparatus will be explained:

If, from the condition shown in FIG. 5, the rotary disk 8 is rotated in the direction shown by the arrow, the pressure roller 2 is moved to the left through the crank 6 and is moved to the right after is reaches a position which is a little ahead of the sharpened front end of portion 1a of the plate-form die 1. When it approaches its original position, the cam plate 14 starts pushing the roller 16. The L-shaped swingable arm 16 is inclined thereby and the pressure plate 15 is elevated so that the plate material a is clamped between the same and the receiving plate 17. Under these conditions, the pressure roller 2 is located below the concavity If so that movement of the plate material a is easily effected. When the cam plate 14 is further rotated, owing to the fact that the swingable arm 16 cannot be further inclined, the slidable frame 13 is moved to the right and the flat plate material a is moved to the right by the predetermined distance S. At the same time, this length of material a is wound on the winding frame 11. As this operation is repeated, there is obtained a winding of the plate material a which has been formed continuously at its center portion with a portion of small thickness. In almost the same manner as mentioned above, the winding is then applied to a rolling machine for being made into a predetermined thickness. Then the same is suitably cut for obtaining contact members, terminal members, reeds of the like.

FIGS. 9 and 10 show a pair of plate-form dies 1 with a space L therebetween. Each die 1 is cut at its outer side so as to be sharpened at its front end portion. With this die arrangement, there is obtained a plate of irregular sectional shape from the plate material a such that its center portion is formed into a large thickness portion of width L. Its opposite sides are formed into small thickness portions as illustrated in FIG. 11. The plate thus obtained is then also subjected to rolling to obtain a product of a predetermined thickness. The resultant strip is then properly cut to produce terminal members, contact members, reeds or the like which are different in form from the above described ones.

FIGS. 12 and 13 show further another embodiment wherein a plate-form die 1 similar to that shown in FIG. 1 is formed to have two steps paced one upon the other. With this die, there can be obtained a plate of irregular sectional shape such that the small thickness portions are formed into two steps as shown in FIG. 14. This is also rolled and then cut for obtaining terminal members or the like which are different in form from the above described ones.

Thus, according to this invention, plate material is thinned out by being gradually squeezed by the sharpened portion of a plate-form die. The resultant product is neither wavey not broken even if the same is further rolled. Thereby, a desired thickness can be obtained. Additionally, continuous working for plate material of great length can be carried out. The apparatus is simple in construction and can be economically obtained.

What is claimed is:

1. An apparatus for forming a plate of irregular sectional shape comprising a plate-form die including a plate surface portion sharpened at a leading end por tion, a pressure roller, means for moving said roller reciprocably within a range corresponding to said plate surface portion for the pressing of a plate material placed on the plate surface portion of the die against said surface portion and means-for moving the plate material, after each reciprocable movement of the pressure roller, through a predetermined distance rearwardly from the leading end portion of the die.

2. Apparatus as claimed in claim 1, wherein said surface portion includes opposite side edges and a tip end which are formed into respective slanted surfaces.

3. Apparatus as claimed in claim 1, wherein said surface portion includes a portion having parallel side edges extending from the rear end of the leading end portion to serve as a guide for movement of the plate material.

4. Apparatus as claimed in claim 1, comprising pressing means for applying adjustable: pressure above the pressure roller, said means for moving the plate material including a clamp-type travelling means operable at each completion of a reciprocating movement of the pressure roller, such that the plate material is passed through between the pressure roller and the plate-form die by a predetermined length.

5. Apparatus as claimed in claim 4 comprising a machine frame for supporting the pressure roller, a machine base, rollers for supporting said frame on said base, a crank connected to the machine frame, and a rotary disk for driving said crank.

6. An apparatus as claimed in claim 5 comprising a cam on said disk, an L-shaped swingable arm having one end engaged with said cam and including at a second end a pressure plate adapted for being moved by movement of the swingable arm caused by the cam to clamp the plate material.

7. Apparatus as claimed in claim I wherein said plate-form die includes a multi-step plate surface portion each step of which includes a leading end portion.

8. Apparatus as claimed in claim 1 wherein said plate-form die includes at least two laterally spaced parts separated by a groove.

9. Apparatus as claimed in claim I wherein said lead ing end portion includes a chamfered portion.

I0. Apparatus as claimed in claim 1 wherein said lead end portion includes slanted edges having an angle of relief between about 15 and 45.

lll. Apparatus as claimed in claim 1 wherein said leading end portion is wedge shaped and said plate surface portion is flat. 

1. An apparatus for forming a plate of irregular sectional shape comprising a plate-form die including a plate surface portion sharpened at a leading end portion, a pressure roller, means for moving said roller reciprocably within a range corresponding to said plate surface portion for the pressing of a plate material placed on the plate surface portion of the die against said surface portion and means for moving the plate material, after each reciprocable movement of the pressure roller, through a predetermined distance rearwardly from the leading end portion of the die.
 2. Apparatus as claimed in claim 1, wherein said surface portion includes opposite side edges and a tip end which are formed into respective slanted surfaces.
 3. Apparatus as claimed in claim 1, wherein said surface portion includes a portion having parallel side edges extending from the rear end of the leading end portion to serve as a guide for movement of the plate material.
 4. Apparatus as claimed in claim 1, comprising pressing means for applying adjustable pressure above the pressure roller, said means for moving the plate material including a clamp-type travelling means operable at each completion of a reciprocating movement of the pressure roller, such that the plate material is passed through between the pressure roller and the plate-form die by a predetermined length.
 5. Apparatus as claimed in claim 4 comprising a machine frame for supporting the pressure roller, a machine base, rollers for supporting said frame on said base, a crank connected to the machine frame, and a rotary disk for driving said crank.
 6. An apparatus as claimed in claim 5 comprising a cam on said disk, an L-shaped swingable arm having one end engaged with said cam and including at a second end a pressure plate adapted for being moved by movement of the swingable arm caused by the cam to clamp the plate material.
 7. Apparatus as claimed in claim 1 wherein said plate-form die includes a multi-step plate surface portion each step of which includes a leading end portion.
 8. Apparatus as claimed in claim 1 wherein said plate-form die includes at least two laterally spaced parts separated by a groove.
 9. Apparatus as claimed in claim 1 wherein said leading end portion includes a chamfered portion.
 10. Apparatus as claimed in claim 1 wherein said lead end portion includes slanted edges having an angle of relief between about 15* and 45*.
 11. Apparatus as claimed in claim 1 wherein said leading end portion is wedge shaped and said plate surface portion is flat. 